Abstract:

An electrical connector assembly including a mounting ring having an
interior region, a sealing surface at one axial end for securing to a
surface, and a securement rim at an opposite axial end. A connector body
having engagement surfaces can engage and seal to the mounting ring. The
connector body can include electrical terminals extending into the
interior region of the mounting ring for engaging mating electrical
terminals.

Claims:

1. An electrical connector assembly comprising:a mounting ring having an
interior region, a sealing surface at one axial end for securing to a
surface, and a securement rim at an opposite axial end; anda connector
body having engagement surfaces for engaging and sealing to the mounting
ring, the connector body including electrical terminals extending into
the interior region of the mounting ring for engaging mating electrical
terminals.

2. The assembly of claim 1 in which the connector body engages and locks
to the securement rim of the mounting ring.

3. The assembly of claim 2 in which the mounting ring includes an adhesive
layer on the sealing surface.

4. The assembly of claim 3 in which the mounting ring engages a recess in
the connector body.

5. The assembly of claim 4 in which the connector body includes an
adhesive layer.

6. The assembly of claim 5 in which the electrical terminals comprise at
least four female electrical terminals with circular resilient sockets.

7. The assembly of claim 6 in which the female electrical terminals are
electrically connected in electrical circuitry including bypass
circuitry.

8. The assembly of claim 7 in which the electrical circuitry includes
diodes.

9. The assembly of claim 7 further comprising a removable cover for
providing access to the electrical circuitry.

10. The assembly of claim 1 in which the electrical terminals are
electrically connected to cables extending from the connector body.

11. The assembly of claim 1 further comprising a solar panel having an
electrical connection region with protruding circular male terminals, the
mounting ring being secured around the electrical connection region
whereby the circular male terminals protrude into the interior region of
the mounting ring for engagement with female electrical terminals of the
connector body which have circular resilient sockets.

12. The assembly of claim 11 further comprising laminating material
applied to surround the mounting ring, the mounting ring blocking entry
of the laminating material into the electrical connection region.

13. A method of forming an electrical connection with an electrical
connector assembly having a mounting ring and a connector body
comprising:securing the mounting ring to a surface, the mounting ring
having an interior region, a sealing surface at one axial end for
securing to the surface, and a securement rim at an opposite axial end;
andengaging and sealing engagement surfaces of the connector body to the
mounting ring, the connector body including electrical terminals
extending into the interior region of the mounting ring which engage
mating electrical terminals protruding from the surface into the interior
of the mounting ring.

14. The method of claim 13 further comprising engaging and locking the
connector body to the securement rim of the mounting ring.

15. The method of claim 14 further comprising securing the mounting ring
with an adhesive layer on the sealing surface.

16. The method of claim 15 further comprising engaging the mounting ring
in a recess in the connector body.

17. The method of claim 16 further comprising providing the connector body
with an adhesive layer.

18. The method of claim 17 further comprising providing the electrical
terminals with at least four female electrical terminals having circular
resilient sockets.

19. The method of claim 18 further comprising electrically connecting the
female electrical terminals in electrical circuitry including bypass
circuitry.

20. The method of claim 19 further comprising providing the electrical
circuitry with diodes.

21. The method of claim 19 further comprising providing access to the
electrical circuitry with a removable cover.

22. The method of claim 13 further comprising electrically connecting the
electrical terminals to cables extending from the connector body.

23. The method of claim 13 further comprising securing the mounting ring
around an electrical connection region of a solar panel having circular
male terminals protruding into the interior region of the mounting ring
which engage female electrical terminals of the connector body which have
circular resilient sockets.

24. The method of claim 23 further comprising applying laminating material
surrounding the mounting ring, the mounting ring blocking entry of the
laminating material into the electrical connection region.

Description:

RELATED APPLICATIONS

[0001]This application is a divisional of U.S. application Ser. No.
11/803,017, filed on May 11, 2007, which claims the benefit of U.S.
Provisional Application No. 60/800,534, filed on May 15, 2006, U.S.
Provisional Application No. 60/849,633, filed on Oct. 5, 2006, and U.S.
Provisional Application No. 60/920,382, filed on Mar. 28, 2007. The
entire teachings of the above applications are incorporated herein by
reference.

BACKGROUND

[0002]Solar panels are typically electrically connected together on site
during installation. Current methods tend to be labor intensive and may
include soldering on site. As a result, installation can be time
consuming.

SUMMARY

[0003]The present invention can provide an electrical connector assembly
that can allow solar panels to be electrically connected together easily
and quickly.

[0004]The electrical connector assembly can include a mounting ring having
an interior region, a sealing surface at one axial end for securing to a
surface, and a securement rim at an opposite axial end. A connector body
having engagement surfaces can engage and seal to the mounting ring. The
connector body can include electrical terminals extending into the
interior region of the mounting ring for engaging mating electrical
terminals.

[0005]In particular embodiments, the connector body can engage and lock to
the securement rim of the mounting ring. The mounting ring can include an
adhesive layer on the sealing surface. The mounting ring can engage a
recess in the connector body. The connector body can include an adhesive
layer. The electrical terminals can include at least four female
electrical terminals with circular resilient sockets. The female
electrical terminals can be electrically connected in electrical
circuitry including bypass circuitry. The electrical circuitry can
include diodes. A removable cover can provide access to the electrical
circuitry. The electrical terminals can be electrically connected to
cables extending from the connector body. The electrical connector
assembly can further include a solar panel having an electrical
connection region with protruding circular male terminals. The mounting
ring can be secured around the electrical connection region whereby the
circular male terminals protrude into the interior region of the mounting
ring for engagement with female electrical terminals of the connector
body which have circular resilient sockets. A laminating material can be
applied and can be turned into liquid form to surround the mounting ring.
The mounting ring can block entry of the laminating material into the
electrical connection region.

[0006]The present invention can also provide an electrical connector
assembly including an electrical connector body and female electrical
terminals with circular resilient sockets contained within the body. The
circular resilient sockets can be positioned along an electrical
engagement face of the body. The electrical engagement face can have a
planar sealing surface surrounding the circular resilient sockets for
engaging a surface and sealing around the circular resilient sockets.

[0007]In particular embodiments, an adhesive layer can be included on the
planar sealing surface. The female electrical terminals can be
electrically connected in electrical circuitry including bypass
circuitry. The electrical circuitry can include diodes. The electrical
terminals can be electrically connected to a circuit board containing the
electrical circuitry. A removable cover can provide access to the
electrical circuitry. The electrical cables can be electrically connected
to the electrical terminals and extend from the connector body. The
electrical connector assembly can further include a solar panel having an
electrical connection region with protruding circular male terminals for
engagement with the circular resilient sockets of the female electrical
terminals. The solar panel can include laminating material. The connector
body can be positioned within a hole in the laminating material for
engaging the circular male terminals. The circular male terminals can be
located at a bottom of the hole.

[0008]The present invention can also provide an electrical connector
assembly including an enclosed housing having an openable access cover
covering an access opening. An electrical engagement face can be
positioned on the housing opposite to the access opening. At least one
electrical connection opening can extend through the electrical
engagement face. An electrical connector board can have electrical
terminals secured thereon and can be insertable within the housing
through the access opening. A self locking and alignment arrangement can
lock the electrical connector board within the housing and align the
electrical terminals with the at least one electrical connection opening
of the electrical engagement face for engaging mating electrical
terminals protruding through the at least one opening in the electrical
engagement face.

[0009]In particular embodiments, an adhesive layer can be on the
electrical engagement face and surround the at least one opening for
securing the housing to a surface. A pressure relief valve can be
included on the housing for relieving pressure differences within the
housing. The electrical terminals on the electrical connector board can
be female electrical terminals with circular resilient sockets. The at
least one electrical connection opening can include a series of
electrical connection openings. The circular resilient sockets can be
aligned with corresponding electrical connection openings. The female
electrical terminals can be electrically connected in electrical
circuitry including bypass circuitry. The electrical circuitry can
include diodes. The electrical terminals can be electrically connected to
a circuit board containing the electrical circuitry. The electrical
terminals can be mounted to the electrical connection connector board in
alignment with visual alignment holes extending through the electrical
connector board for allowing visual alignment of the circular resilient
sockets with mating male electrical terminals. The locking and alignment
arrangement can include self-locking protrusions extending from the
housing which engage corresponding locking holes in the electrical
connector board. The electrical connector assembly can also include a
solar panel having an electrical connection region with protruding
circular male terminals extending through corresponding electrical
connection openings in the electrical engagement face for engagement with
the circular resilient sockets of the female electrical terminals. The
solar panel can include laminating material. The housing can be
positioned within a hole in the laminating material from engaging the
circular male terminals. The circular male terminals can be located at a
bottom of the hole.

[0010]The present invention can also provide a method of forming an
electrical connection with an electrical connector assembly having a
mounting ring and a connector body. The mounting ring can be secured to a
surface. The mounting ring can have an interior region, a sealing surface
at one axial end for securing to the surface, and a securement rim at an
opposite axial end. Engagement surfaces of the connector body can be
engaged and sealed to the mounting ring. The connector body can include
electrical terminals extending into the interior region of the mounting
ring which engage mating electrical terminals protruding from the surface
into the interior of the mounting ring.

[0011]In particular embodiments, the connector body can be engaged and
locked to the securement rim of the mounting ring. The mounting ring can
be secured to the surface with an adhesive layer on the sealing surface.
The mounting ring can be engaged in a recess in the connector body. The
connector body can be provided with an adhesive layer. The electrical
terminals include at least four female electrical terminals having
circular resilient sockets. The female electrical terminals can be
electrically connected in electrical circuitry including bypass
circuitry. An electrical circuitry can include diodes. A removable cover
can provide access to the electrical circuitry. The electrical terminals
can be electrically connected to cables extending from the connector
body. The mounting ring can be secured around an electrical connection
region of a solar panel having circular male terminals which protrude
into the interior region of the mounting ring and engage female
electrical terminals of the connector body having circular resilient
sockets. Laminating material can be applied and can be turned into liquid
form to surround the mounting ring. The mounting ring can block entry of
the laminating material into the electrical connection region.

[0012]The present invention can also provide a method of forming an
electrical connection with an electrical connector assembly. Female
electrical terminals with circular resilient sockets can be contained
within an electrical connector body. The circular resilient sockets can
be positioned along an electrical engagement face of the body. The
Electrical engagement face can have a planar sealing surface surrounding
the circular resilient sockets. The sealing surface of the electrical
engagement face can engage a surface for sealing around the circular
resilient sockets and for electrically engaging the circular resilient
sockets with mating male circular terminals protruding from the surface.

[0013]In particular embodiments, the electrical engagement face can be
secured to the surface with an adhesive layer on the planar sealing
surface. The female electrical terminals can be electrically connected in
electrical circuitry including bypass circuitry. The electrical circuitry
can include diodes. The female electrical terminals can be electrically
connected to a circuit board containing the electrical circuitry. A
removable cover can provide access to the electrical circuitry. The
female electrical terminals can be electrically connected to electrical
cables extending from the connector body. The electrical connector body
can be electrically connected to a solar panel having an electrical
connection region at which the mating circular male terminals protrude
from the surface. The solar panel can include laminating material and the
connector body can be positioned within a hole in the laminating material
for engaging the circular male terminals. The circular male terminals can
be located at a bottom of the hole.

[0014]The present invention can also provide method of forming an
electrical connection with an electrical connector assembly in which an
enclosed housing can be provided having an openable access cover covering
an access opening. An electrical engagement face can be positioned on the
housing opposite the access opening. At least one electrical connection
opening can extend through the electrical engagement face. An electrical
connector board having electrical terminals secured thereon can be
inserted within the housing through the access opening. The electrical
connector board can be locked within the housing and align the electrical
terminals with the at least one electrical connection opening of the
electrical engagement face with a self-locking and alignment arrangement,
to engage mating electrical terminals that protrude through the at least
one electrical connection opening in the electrical engagement face.

[0015]In particular embodiments, the housing can be secured to a surface
with an adhesive layer on the electrical engagement face surrounding the
at least one electrical connection opening. Pressure differences within
the housing can be relieved by a pressure relief valve. The electrical
terminals on the electrical connector board can be female electrical
terminals with circular resilient sockets. The at least one electrical
connection opening can include a series of electrical connection
openings. The circular resilient sockets can be aligned with
corresponding electrical connection openings. The female electrical
terminals can be electrically connected in electrical circuitry including
bypass circuitry. The electrical circuitry can include diodes. The female
electrical terminals can be electrically connected to a circuit board
containing the electrical circuitry. The female electrical terminals can
be mounted to the electrical connector board in alignment with visual
alignment holes extending through the electrical connector board for
allowing visual alignment of the circular resilient sockets with mating
male electrical terminals. Self-locking protrusions of the self-locking
and alignment arrangement can extend from the housing and engage
corresponding locking holes in the electrical connector board. The
housing can be electrically connected to a solar panel having an
electrical connection region at which the mating electrical terminals are
circular male terminals protruding from the surface at the electrical
connection region into respective electrical connection openings for
engaging corresponding circular resilient sockets. The solar panel can
include laminating material. The housing can be positioned within a hole
in the laminating material for engaging the circular male terminals. The
circular male terminals can be located at a bottom of the hole.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]The foregoing will be apparent from the following more particular
description of example embodiments of the invention, as illustrated in
the accompanying drawings in which like reference characters refer to the
same parts throughout the different views. The drawings are not
necessarily to scale, emphasis instead being placed upon illustrating
embodiments of the present invention.

[0038]FIG. 23 is a plan view of another embodiment of an electrical
connector assembly on a solar panel.

[0039]FIG. 24 is a sectional view through a laminated solar panel showing
the electrical connector assembly of FIG. 23.

[0040]FIG. 25 is a perspective view of the electrical connector assembly
of FIG. 23.

[0041]FIG. 26 is a bottom view of the electrical connector assembly of
FIG. 23.

[0042]FIG. 27 is a partial sectional view of the electrical connector
assembly of FIG. 23 positioned within a hole in the laminating material
of the solar panel.

[0043]FIG. 28 is a perspective view of another electrical connector
assembly.

[0044]FIG. 29 is a perspective view of the electrical connector assembly
of FIG. 28 with the cover removed to show a circuit board.

[0045]FIG. 30 is a perspective view of the electrical connector assembly
of FIG. 28 with the cover and circuit board removed.

[0046]FIG. 31 is a bottom view of the electrical connector assembly of
FIG. 28.

DETAILED DESCRIPTION

[0047]Referring to FIGS. 1 and 2, solar panel 10 has a series of solar
cells 12 that are electrically connected to conductors 14. Selected
conductors 14 can terminate at, or be electrically connected to
electrical terminals 16a which can protrude from a planar mounting
surface 38 located at an electrical connection region 16, often at the
back of the solar panel 10. There typically can be two or more electrical
terminals 16a, with four being shown in FIG. 1 as an example. The
electrical terminals 16a can be male circular snap button electrical
connector terminals that are soldered or otherwise secured to the
conductors 14 and secured to the surface 38 of the electrical connection
region 16. The male electrical terminals 16a can be similar to those
disclosed in U.S. Pat. No. 7,083,481, the contents of which are
incorporated herein by reference in its entirety. Alternatively, other
suitable electrical connector terminals can be used. The solar panel 10
can be covered with laminating materials 34 (FIG. 7) which can seal out
moisture. The laminating material 34 can include a polymeric material
such as ethyl vinyl acetate (EVA), and also can include or be laminated
with a backing such as a polyvinyl fluoride (PVF) backing or glass
backing 35. The laminating material 34 can be applied in a sheet and
turned into melted liquid form during processing under heat and pressure
during lamination.

[0048]Referring to FIGS. 3-7, electrical junction or connector assembly 20
is one embodiment of an electrical connector assembly which can be
employed to allow electrical connections to be easily and quickly made to
solar panels 10 on site. The electrical connector assembly 20 can include
a connector body 18 with a rounded or circular nose 18a which houses
female electrical connectors 27, for example two, having female
electrical terminals 22, within respective recesses 22a positioned on an
electrical engagement face 21, which can be planar. The recesses 22a can
be sized for each female electrical terminal 22, or alternatively, one
large recess can be employed for housing both female electrical terminals
22. The female electrical terminals 22 can have resilient female circular
connector sockets 23 with a circular pattern of resilient contact tabs
23a (FIG. 11), for engaging the male electrical terminals 16a (FIG. 6),
for example two, for electrical connection therebetween. The electrical
connectors 27 can be similar to those disclosed in U.S. Pat. No.
6,520,812, the contents of which are incorporated herein by reference in
its entirety. The electrical connectors 27 can have securement portions
26, such as a crimping region with crimping tabs for electrical
connection to respective electrical cables, wires or conductors 24. The
electrical cables 24 can extend from the rear 18b of the body 18 for
electrical connection to desired locations and components. The electrical
cables 24 can electrically connect the solar panel 10 to other solar
panels to create an array, which can be in series or in parallel.

[0049]The electrical connector assembly 20 can include a mounting,
securement, or housing member 30 such as a ring. The ring 30 can be
circular or tubular in shape, and have a wall surrounding an interior
region or cavity 36, a sealing surface 29 at one axial end, and a
securement rim 31 at the opposite axial end. The securement rim 31 can be
mechanically engageable or lockable in a sealed manner with engagement
surfaces such as a circular recess or annular groove 28 on the bottom of
the body 18. The sealing surface 29 of the ring 30 can be adhered to the
surface 38 of the solar panel 10 at the electrical connection region 16
around the male electrical terminals 16a. The ring 30 can be adhered
before the laminating material 34 is applied. The ring 30 can include an
adhesive layer 30a, for example double sided adhesive tape, or an
adhesive layer covered by release paper 30b (FIG. 5). The release paper
30b can be removed to allow the ring 30 to be adhered to the surface 38
around the electrical terminals 16a. Alternatively, the ring 30 can be
adhered by an adhesive or sealant applied at the time the ring 30 is
adhered. The laminating material 34 can then be applied and turned into
liquid form over the solar panel 10. The sealing surface 29 at the bottom
of the ring 30 with the adhesive layer 30a can seal against surface 38
which can block or prevent the entry or intrusion of the laminating
material 34 into the electrical connection region 16. The electrical
terminals 16a can be secured to the surface 38 before the ring 30 and
laminating material 34 is applied, or alternatively, can be secured
later. The ring 30 can have a height greater than the height of the
laminating material 34, and can provide a barrier or dam for the
laminating material 34 so that the electrical connection region 16 does
not become covered with laminating material 34, thereby allowing access
to the male electrical terminals 16a for electrical connection. The
height of the ring 30 can depend upon the thickness of the laminating
material 34 and backing 35, and can protrude above the laminating
material 34 and backing 35 for securement to the connector body 18. The
male electrical terminals 16a can have a height that is less than the
ring 30 and of the laminating material 34. Consequently, the ring 30 can
allow access to the male electrical terminals 16a within cavity 36.

[0050]When the laminating material 34 has hardened, forming a hole 33 and
sealing to and around the ring 30, the body 18 of the electrical
connector assembly can be engaged with the ring 30 by engaging securing,
locking or snapping the groove 28 over the engagement rim 31 of the ring
30 and extending the female electrical terminals 22 into the interior
region 36 of the ring 30 and into engagement with the protruding male
electrical terminals 16a at the bottom of the hole 33. Alternatively, the
laminating material 34 and backing 35 can be first applied to the solar
panel 10, and a hole 33 can be later cut to expose the electrical
connection region 16. The ring 30 can then be positioned, secured, and
sealed within the hole 33 to the laminating material for engagement with
the body 18.

[0051]The engagement rim 31 of the ring 30 and the groove 28 can be
configured to have locking and/or water sealing features. Additionally,
sealant material, for example silicone, can be added to increase the
sealing capabilities. The bottom of the body 18 on the electrical
engagement face 21 can include an adhesive layer 32 surrounding the
groove 28 for adhering the body 18 to the laminating material 34 or
backing 35 (FIG. 7). This can provide additional securement and sealing
capabilities, including a planar sealing surface 83, on the electrical
engagement face 21 surrounding the female circular connector sockets 23
of the female electrical terminals 22 for sealing out moisture. Sealant
material can also be added between the body 18 and the laminating
material 34 or backing 35. If the ring 30 is applied to the surface 38
after the male electrical terminals 16a are in place, a locating fixture
or jig can be used to locate the ring 30 into the proper position
relative to the male electrical terminals 16a. Alternately, if the male
electrical terminals 16a are secured or soldered to surface 38 after the
ring 30 is secured in place, a locating fixture or jig can be used to
solder the male electrical terminals 16a in the proper position relative
to each other and the ring 30. The male electrical terminals 16a can
protrude from the surface 38 of the electrical connection region 16 into
the interior region 36 of the ring 30. In some embodiments, the groove 28
in body 18 can be replaced with a cavity in which the diameter of the
cavity engages or snaps onto the ring 30. The body 18 and the ring 30 can
be made of insulative material such as polymers, plastics or ceramics.
The body 18 can have openings 24a to allow the passage of the electrical
cables 24, or which alternatively, can be formed by molding the body 18
over the electrical cables 24.

[0052]Consequently, the solar panels 10 can be shipped with the electrical
connection region 16 having the configuration shown in FIG. 7 so that
electrical connections between solar panels 10 can be made by engaging or
snapping the bodies 18 of the electrical connector assemblies 20 in place
onto the rings 30, whereby the sockets 23 of the female electrical
terminals 22 on electrical engagement face 21 extend into the cavity 36
of ring 30 and also engage the male electrical terminals 16a which are
located below the laminating material 34 in the cavity 36 surrounded by
ring 30. At the same time, the hole 33 and cavity 36 surrounding the male
electrical terminals 16a can be sealed in a watertight manner. The male
electrical terminals 16a can have heads 16b which are wider than the
lower portions 16c for locking the female terminals 22 to the male
electrical terminals 16a. This can reduce the possibility of unwanted
disengagement, for example by heat related expansion and contraction. As
a result, the electrical connector assembly 20 and connector body 18 can
be quickly and easily secured with both electrical and mechanical
engagement in a sealed or watertight manner for electrically connecting
solar panels 10 together. The solar panels 10 can be shipped with a
protective removable cover 37 (FIG. 7) which can engage the ring 30 and
cover the electrical connection region 16.

[0053]FIGS. 8-12 depict another embodiment of an electrical junction or
connector assembly 40 which can have a body 42 with a circular shape. The
electrical connector assembly 40 differs from electrical connector
assembly 20 in that a removable access cover 54 can be secured to the top
of the body 42 within a recess 58 by screws 46 within holes 54a and 58a.
The cover 54 and recess 58 can be shaped to have a close fit and can
include a gasket for sealing purposes. The access cover 54 can provide
access to the inner components and circuitry of the electrical connector
assembly 40. The engagement rim 31 of the ring 30 can have an annular
shoulder 31a for sealing and/or locking purposes. The electrical
connector assembly 40 can have at least four female electrical terminals
22 within recesses 22a on electrical engagement face 21 for mating with
corresponding at least four male electrical terminals 16a on the solar
panel 10. The four electrical terminals 22 can be provided on two single
female electrical connectors 27 and on a dual female electrical connector
50 (FIGS. 10-12). The two female electrical connectors 27 can be
electrically connected to cables 24 at the securement portions 26. The
opposite end of each female electrical connector 27 can include a
connection portion 25 which can be electrically connected to a lead 48a
at one end of a diode 48. The leads 48a at the opposite end of each diode
48 can be electrically connected to the connection portions 25 on the
dual electrical connector 50. The leads 48a can be secured to the
connection portions 25 by screws 46. Washers can be employed if
necessary. The diodes 48 can be positioned within a recess 44 within the
body 42. The diodes 48 can be accessed by removing the cover 54, allowing
replacement of the diodes as well as other components when necessary. The
dual electrical connector 50 can have a jumper 52 electrically connecting
the two female electrical terminals 22 together, which can be stamped
from the same material as the electrical terminals 22. Alternatively, the
electrical terminals 22 can be separate components that are then
connected together to function as the dual electrical connector 50.

[0054]The electrical connector assembly 40 can be secured and connected to
solar panel 10 in a similar manner as previously described. The
electrical conductors 14 and four male terminals 16a can be appropriately
electrically configured on the solar panel 10, and the female electrical
terminals and electrical circuit of connector assembly 40 can be
electrically connected or arranged, to provide electrical bypass
circuitry. As a result, when the solar panel 10 is shaded, or when solar
cells 12 are damaged, the diodes 48 can direct electricity away from the
solar panel 10 so that non productive solar panels 10 do not draw power
away from other productive solar panels 10. In some embodiments, the
connectors 27 and 50 can be positioned within a single cavity which also
engages ring 30. In addition, the electrical connectors 27 and 50 can be
crimped, or soldered to the leads of the diodes 48.

[0055]FIGS. 13-15 depict another embodiment of an electrical junction or
connector assembly 60 which differs from electrical connector assembly 40
in that electrical connector assembly 60 can include two recesses 70, one
for each diode 48, which can be sealed by rubber gaskets 66. The dual
electrical connector 50 can have a longer jumper 52 for accommodating the
positioning of the diodes 48, and the electrical connectors 27 can have
connection portions 25 which are positioned or angled to one side, for
alignment purposes. The cover 54 can be shaped appropriately to cover the
two recesses 70. Electrical connector assembly 60 can be mounted to solar
panel 10 in a manner similar to that described above.

[0056]Referring to FIGS. 16-22 electrical junction or connector assembly
80 can include female electrical terminals 22 which are molded into a
body 82 and are positioned within or along an electrical engagement face
21, which can be planar. Some embodiments have two or three female
electrical terminals 22, and others have four as shown. A planar sealing
surface 83 can be on the electrical engagement face 21 and can surround
the female electrical terminals 22 for engaging surface 38 and sealing
around the female electrical terminals 22. The body 82 can have a
rectangular outer perimeter and a generally flat upper surface. The
electrical terminals 22 can be provided on electrical connectors 27 and
50 which are electrically connected to electrical cables 24. The
electrical cables 24 can extend from the body 82 and can be molded in the
body 82. Diodes 48 can be electrically connected to the female electrical
terminals 22 in a manner similar to that described above and in a circuit
that can provide bypass circuitry. Access to the diodes 48, circuitry,
and other components can be provided by a cover 84 which can be removably
secured to the body 82 by screws 46 or other suitable means for
maintenance and replacement of components. The female circular connector
sockets 23 on the electrical engagement face 21 of the electrical
connector assembly 80 can be engaged onto the mating male electrical
terminals 16a at the electrical connection region 16 of the solar panel
10. An adhesive layer 32 can be included (FIG. 20) on the electrical
engagement face 21 on the sealing surface 83 around the female circular
connector sockets 23 of the female electrical terminals 22 for securing
the electrical engagement face 21 to surface 38 and to provide sealing
around the sockets 23 and the electrical terminals 16a for sealing out
moisture.

[0057]In one embodiment, the laminating material 34 and backing 35 can be
applied over the electrical connector assembly 80, in an encapsulating
manner (FIG. 18). If desired, a hole can be cut in the laminating
material 34 and backing 35 to provide access to the electrical connector
assembly 80. In another embodiment, referring to FIG. 21, a hole 33 can
be cut in the laminating material 34 and backing 35, allowing the
electrical connector assembly 80 and electrical engagement face 21 to be
positioned within the hole 33 for securement to the surface 38 of the
electrical connection region 16, and for engagement with the male
electrical terminals 16a located on surface 38 at the bottom of the hole
33. The height of the laminating material 34 and backing 35 can be the
same height as the electrical connector assembly 80 to result in a flush
surface. Sealant can be applied around the perimeter of the electrical
connector assembly 80 for sealing purposes. Alternatively, a rectangular
mounting or housing member or ring 85 (FIG. 22) can be adhered to the
solar panel 10 with adhesive layer 30a and used to provide an area in
which the electrical connector assembly 80 can be positioned within. The
ring 85 can have an inner sealing surface 85a which can engage against
and seal around the perimeter of the body 82 of the electrical connector
assembly 80. The ring 85 can be positioned on the solar panel 10 around
electrical connection region 16, before the laminating material 34 is
applied, or after the laminating material 34 is applied, and a hole 33
being cut for positioning the ring 85 therein. It is understood that the
electrical connector assembly 80 can have less than four or more than
four female electrical connectors 22.

[0058]Referring to FIGS. 23-27, electrical junction or connector assembly
90 differs from electrical connector assembly 80 in that electrical
connector assembly 90 can include a circuit board 94 electrically
connected to female electrical terminals 22 and electrical cables 24. A
body 92 can be positioned or molded over the female electrical terminals
22 and the circuit board 94. A cover 84 can provide access to the
interior, circuitry, and to the diodes 48 for maintenance and replacement
of components. The circuit board 94 can include circuitry that carries or
directs the current received from the solar panel 10 through the
electrical terminals 16a and out the electrical cables 24. The circuitry
can regulate current and voltage, for example, in the event of over
heating or a lightening strike, and can provide bypass circuitry. The
circuit board 94 can eliminate the need for replaceable diodes or heat
sinks. The circuit board 94 can also contain logic for other desired
functions. In some embodiments, the whole circuit board 94 can be
encapsulated in the body 92. The electrical connector assembly 90 can be
laminated or encapsulated such as shown in FIG. 24, positioned within a
hole 33 as shown in FIG. 27, or can be used in conjunction with a
rectangular ring 85 (FIG. 22) in a manner similar to that described for
electrical connector assembly 80.

[0059]FIGS. 28-31 depict another embodiment of an electrical junction or
connector assembly 100. The electrical connector assembly 100 can have a
generally rectangular housing 102 that forms a junction box. The housing
102 can have an openable access cover 104 with hinges 112 and protrusions
114 that engage latches 116 for covering an access opening 101. The
access opening 101 can face or be in line with the bottom 132 of the
housing 102. The electrical engagement face 21 is located on the opposite
or underside of the bottom 132 and can be planar. A protrusion 115 can
allow the cover 104 to be lifted or opened for allowing access within the
housing 102. It is understood that other suitable covers can be employed
and can be secured with fasteners. Openings 106 and 108 can be located on
opposite walls, sides or ends 105 of the housing 102 to allow electrical
cables 24 to enter the housing 102 for electrical connection therein. The
opening 108 can have a fitting 108a as shown, to provide sealing around
electrical cable 24. Such a fitting 108a can also be provided for opening
106. An opening 110 can be located on one wall or side 107 for mounting a
pressure relief member, valve or vent 110a for relieving pressure
differences, such as pressure built up within housing 102, or equalizing
pressure. A gasket 103 can be employed to provide watertight sealing for
the cover 104 and housing 102.

[0060]An electrical connector, electrical or circuit member or board 118
(FIG. 29) can be inserted in line through the access opening 101 and
snapped, engaged, or secured in place in a desired alignment within the
housing 102 by a locking arrangement 127. The locking arrangement 127 can
be self-locking and can include a series of self-locking protrusions 128
extending from the bottom 132 of the housing 102. The protrusions 128 can
engage corresponding locking holes 126 within the circuit board 118 to
lock the circuit board 118 in position. This can provide a quick
self-locking alignment arrangement and can fix or secure the circuit
board 118 in a predetermined position relative to the housing 102. For
example, four locking protrusions 128 and holes 126 are shown at four
corners to provide the desire locking and alignment characteristics. The
locking protrusions 128 and holes 126 can be generally rectangular in
shape. The locking protrusions 128 can have angled locking heads 128a.
The locking arrangement 127 can provide simultaneous horizontal and
vertical locking and alignment of the circuit board 118 in one
engagement, securement or snapping operation of the locking protrusions
128 with holes 126. The circuit board 118 can be inserted into housing
102 through access opening 101 in line and in the same orientation that
it engages the locking arrangement 127. The locking protrusions 128 can
be resilient or flexible, and can be configured to also be releasable,
and can provide a quick release. It is understood that the locking
protrusions 128 and holes 126 can have other shapes or configurations. In
addition, the locking arrangement 127 can employ other suitable locking
features. The circuit board 118 can be shaped to engage the sides 105 and
107 of the housing 102 for alignment purposes, and can be generally
rectangular. The circuit board 118 can also have notches 118a for
engaging surfaces or structures 120 extending from the bottom 132 of the
housing 102. This can also provide alignment. The structures 120 can also
provide sealing and isolate openings 106 and 108. In addition, the
housing 102 can have other suitable structures for alignment.
Alternatively, the circuit board 118 can be held in place by other
suitable means, including fasteners.

[0061]The circuit board 118 can include electrical connectors 140 and 146
on the underside, having electrical terminals 22 with resilient circular
sockets 23. The sockets 23 can be aligned with holes 122 in the circuit
board 118 to provide visual alignment through the circuit board 118. The
locking arrangement 127 can align the resilient circular sockets 23 with
corresponding electrical connection openings or holes 136 in the bottom
132 of the housing 102 (FIG. 31) on the electrical engagement face 21
through which the male electrical terminals 16a on surface 38 of solar
panel 10 can extend or protrude for engagement. The sockets 23 can be
positioned in alignment, over, adjacent, or in the electrical connection
holes 136, depending upon the situation at hand. The electrical
engagement face 21 is on the opposite side of the housing 102 from the
access opening 101 and allows for easy access and alignment for circuit
board 118. A series of holes 124 in the circuit board 118 can allow the
attachment and placement of diodes 48 and jumper wires or conductors
relative to the electrical connectors 140 and 146 on the upper surface.
The electrical connectors 140 and 146 can be held in place with
securement members, tabs 134 or fasteners on the bottom of the circuit
board 118. Alternatively, the electrical connectors 140 and 146 can be
held in place on the bottom 132 of the housing 102.

[0062]The electrical connectors 140 and 146 can have various crimping tabs
138 for crimping to electrical wires, conductors, diodes 48 or jumpers to
obtain the desired electrical circuit, including bypass circuitry. In
addition, a circuit 125 electrically connected to the electrical
connectors 140 and 146 can be included on the circuit board 118 for
providing desired functions. The circuit 125 can be a circuit board that
is electrically connected to circuit board 118, or can be circuitry
formed onto the circuit board 118, and can include desired logic
circuitry. Furthermore, the circuitry provided by the diodes 48,
function, and arrangement thereof, can be formed onto the circuit board
118. The circuit board 118 can be formed of various suitable materials
depending upon whether components are to be merely secured thereto, or
formed thereon. Although the circuit board 118 has been shown to be
generally planar and rectangular in shape, circuit board 118 can have
other suitable shapes, and can be shaped to fit in different shaped
housings 102. In addition, the electrical connectors 140 and 146 can be
positioned on the upper side of circuit board 118.

[0063]The electrical connection holes 136 in the bottom of the housing 102
can be aligned with, or positioned over or around the corresponding
mating male terminals 16a on the surface 38 of the electrical connection
region 16 of the solar panel 10. The mating male terminals 16a can
protrude through the holes 136 into the housing 102 and engage the
sockets 23 of the female electrical connectors 140 and 146. The access
opening 101, the holes 122 in the circuit board 118, and the electrical
connection holes 136 in the bottom of the housing 102, can together allow
inline visual alignment of the female circular sockets 23 with the mating
male terminals 16a. Depending upon the number of electrical connectors
140 and 146, the configuration and positioning, different circuit boards
118 with different electrical circuitry and electrical connector
configurations can be positioned and secured in place into housing 102.
Although five sockets 23 are shown in FIG. 30, it is understood that more
than five or less than five can be employed and positioned in different
patterns. It is understood that the electrical connectors can have other
suitable configurations depending upon the desired circuit.

[0064]The underside of the bottom 132 of the housing 102 on the electrical
engagement face 21, can have an adhesive layer 32, such as silicone or an
adhesive tape, for securing the bottom 132 of the housing 102 in place to
the surface 38 of the electrical connection region 16. This can also
provide a planar sealing surface 83 on the electrical engagement face 21
around the electrical connector sockets 23 and the male electrical
terminals 16a, for sealing out moisture. Adhesives or sealants can also
be applied at the time of adhesion to a surface 38. The electrical
connector assembly 100 can be secured to the solar panel 10 in various
manners such as those previously discussed. In one embodiment, the
housing 102 can be positioned in place after lamination and can be
inserted into a hole 33. During installation, the housing 102 can be
first adhered, secured, or sealed to the surface 38 of the solar panel 10
by adhesive layer 32. The circuit board 118 can then be snapped into the
housing 102, and at the same time the female electrical terminals 22
engage the male electrical terminals 16a protruding from the surface 38
of the electrical connection region 16 at the bottom of the hole 33.
Alternatively, the circuit board 118 can already be positioned or secured
within the housing 102, and then the housing 102 is secured to the
surface 38 while at the same time the female electrical terminals 22
engage the male electrical terminals 16a. A ring 85 (FIG. 22) can be
employed if desired. In addition, the ring 85 can be used before the
laminating material is applied. In another embodiment, the housing 102
can be adhered to the electrical connection region 16 and then the
laminating material 34 is applied around the housing 102. Different
circuit boards 118 with different electrical connector configurations can
be used in conjunction with different male terminal 16a patterns. The
electrical face 21 can have a series of electrical connection holes 136
which can be used with the different electrical connection
configurations. Alternatively, the holes 136 can be different for
different housings 102.

[0065]While this invention has been particularly shown and described with
references to example embodiments thereof, it will be understood by those
skilled in the art that various changes in form and details may be made
therein without departing from the scope of the invention encompassed by
the appended claims.

[0066]For example, the electrical terminals on the solar panel 10 can be
female connectors and the electrical terminals on the electrical
connector assemblies can be male terminals. In addition, other suitable
types of electrical terminals can be employed, such as blade or pin
connectors, etc. Furthermore, although particular shapes have been
described for embodiments of the electrical connector assembles, it is
understood that other suitable shapes are contemplated. The rings 30 and
85 can be of other suitable shapes, including other curved and polygonal
shapes, and combinations of curved and polygonal shapes. Also, although
adhesives have been described for securement of components of the
electrical connector assemblies to the solar panels, it is understood
that other means of securement can be employed, including the use of
fasteners. In some embodiments, seals such as "O" rings can be used for
sealing purposes. In situations where electrical terminals extend above
the laminating materials of the solar panels, the electrical connector
assemblies do not need to be positioned inside holes in the laminating
material. Although the electrical connector assembles have been described
for electrically connecting solar panels, it is understood that the
electrical connector assemblies can be used in other fields for
electrically connecting other types of components.